Bobbin assembly

ABSTRACT

A bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enameled wire wound on the bobbin, and a supply lead electrically connected to one end of the wire of the coil, including a projection on a flange of the bobbin, and a connector element having a first portion crimped about an end portion of the wire of the coil and the supply lead and having a second portion crimped about the supply lead and the projection on the flange of the bobbin.

United States Patent I 72] I nventor Daniel Dumeige Amiens', France |2l| Appl. No. 86,818- [22] Filed Nov. 4, 1970 [45] Patented Sept. 28, 1971 I73] Assignee AMP Incorporated Harrisburg, Pa. [32] Priority Nov. 18, 1969 [33] France [31] 69,39690 [54] BOBBIN ASSEMBLY 6 Claims, 3 Drawing Figs.

[52] US. Cl 336/192, 336/208, 339/95 R, 339/223 [51] lnt.Cl 1101f 15/10 [50] Field of Search 336/192,

198, 208; 242/] 18, I 18.4; 339/223, 275 A, 276 C, 95 R, 276T [56] References Cited UNITED STATES PATENTS 2,718,627 9/1955 Swenson 339/276 T 3,051,773 8/l962 Batcheller 339/276 T X 3,496,504 2/1970 Daley 336/192 X Primary Examiner-Thomas J. Kozma Attorneys-William J. Kcating, Ronald D. Grefe, Gerald K.

Kita, Frederick W. Raring, Jay L. Seitchik and John P. Vandenburg ABSTRACT: A bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enameled wire wound on the bobbin, and a supply lead electrically connected to one end of the wire of the coil, including a projection on a flange of the bobbin, and a connector element having a first portion crimped about an end portion of the wire of the coil and the supply lead and having a second portion crimped about the supply lead and the projection on the flange of the bobbin.

BOBBIN ASSEMBLY This invention relates to a bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enameled wire wound on the bobbin, and a supply lead having an electrically conductive core electrically connected to one end of the wire of the coil, and to a bobbin for such an assembly.

Such bobbin assemblies are employed as solenoids or electromagnets, for example in electromagnetic relays or motors.

In some known bobbin assemblies the electrical connection between the coil wire end and the supply lead is made with the use of a connector element comprising a first portion for connection to the wire end and the lead, which first portion may be formed as a soldering tag or as a crimping ferrule, and a second portion for insertion in an aperture in a flange of the bobbin, the second portion having serrations along its edges for the purpose of retaining the element securely in the aperture.

Another known method of securing the connector element to the bobbin flange is to rivet the element in position.

A disadvantage of these known bobbin assemblies is that the electrical connection between the coil wire end and the supply lead must withstand any tensile stresses to which the supply lead is subjected.

Another disadvantage of these known assemblies is that they require two operations for assembly, the connector element being connected to the bobbin in a first operation, and the wire end and the supply lead being connected to the connector element in a second operation.

A further disadvantage of these known assemblies is that the enamel coating must be removed from an end portion of the coil wire before the electrical connection to the supply lead is made.

According to the present invention, a bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enameled wire wound on the bobbin, and a supply lead electrically connected to one end of the wire of the coil, includes a projection on a flange of the bobbin, and a connector element having a first portion crimped about an end portion of the wire of the coil and. the supply lead, and having a second portion crimped about the supply lead and the projection on the flange of the bobbin.

One embodiment of an assembly in accordance with the present invention will now be described by way of example with reference to the drawing in which:

HO. 1 is a perspective view of part of the assembly;

FIG. 2 is a fragmentary plan view of a detail of the assembly; and

FIG. 3 is a partly cross-sectional side elevation of the detail of FIG. 2.

The bobbin assembly comprises a flanged bobbin 1 of electrically insulating material having flanges 2 and 3, a coil 4 of enameled wire 5 wound on the bobbin 1, and an insulated supply lead 6 having an electrically conductive core 7.

The flange 2 carries two projections 8 and 9, each in the form of a tube having a longitudinally extending open seam through which the supply lead 6 can be inserted into the projection 8 or9. Two channels 14 extend across the flange 2 each in line with an individual one of the projections 8 and 9.

The assembly also includes a connector element 10 having a first portion 11 and a second portion 12, each portion 11 or 12 being in the form of a crimping ferrule, and the two portions 11 and 12 being integrally formed. The portion 11 has a plurality of inwardly extending serrations 13, (FlG. 3) the purpose of which will be described below.

In assembly, the insulation is tripped from an end portion of the lead 6 to expose the electrically conductive core 7 of the lead 6, and the exposed portion of the core 7 is then inserted into the projection 8 together with an end portion of the wire 5 of the coil 4, to project beyond the free end of the projection 8. Due to the open seam, the projection 8 is resilient and grips the insulation of the lead 6 and the wire 5 thereby holding them in position for the subsequent electrical connection operation. The channel 14 serves to guide the wire 5 into the pro'ection 8.

he connector element 10 is then arranged with the bared core 7 of the lead 6 and an end portion of the wire 5 positioned in the crimping ferrule portion 11, and with the projection 8, containing the lead 6 and wire 5, positioned in the crimping ferrule portion 12. The two portions 11 and 12 of the connector element 10 are then simultaneously crimped about the members positioned within them. The serrations 13 in the first portion 11 of the connector 10 break through the enamel coating on the wire 5 during the crimping operation and thus an electrical connection is established between the core 7 of the lead 6 and the wire 5 by the first portion 11 of the connector element 10. The crimping of the second portion 12 of the connector element 10 about the projection 8 serves mechanically to secure the connector element 10 to the bobbin 1, and thus the electrical connection between the lead 6 and the wire 5 is relieved of any tensile stresses to which the lead 6 may be subsequently subjected.

It will be appreciated that the other end of the wire 5 of the coil 4 can be similarly connected to a further supply lead using a further connector element 10 and the projection 9 on the flange 2.

I claim:

1. A bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enamelled wire wound on the bobbin, and a supply lead electrically connected to one end of the wire of the coil, including a projection on a flange of the bobbin, and a connector element having a first portion crimped about an end portion of the wire of the coil and the supply lead and having a second portion crimped about the supply lead and the projection on the flange of the bobbin.

2. An assembly according to claim 1, in which the supply lead is insulated, the first portion of the connector element being crimped about a bared portion of an electrically conductive core of the supply lead, and the second portion of the connector element being crimped about the insulation of the supply lead.

3. An assembly according to claim 1, in which the projection is in the form of a tube having a longitudinally extending open seam, the supply lead being positioned within the projection.

4. An assembly according to claim 3, in which the wire of the coil passes through the projection.

5. An assembly according to claim 4, including a channel in the flange of the bobbin in line with the projection and serving to guide the wire of the coil into the projection.

6. An assembly according to claim 1, in which the first portion of the connector element has a plurality of inwardly extending serrations which serve to break through the enamel coating on the wire of the coil during the crimping operation. 

1. A bobbin assembly comprising a flanged bobbin of electrically insulating material, a coil of enamelled wire wound on the bobbin, and a supply lead electrically connected to one end of the wire of the coil, including a projection on a flange of the bobbin, and a connector element having a first portion crimped about an end portion of the wire of the coil and the supply lead and having a second portion crimped about the supply lead and the projection on the flange of the bobbin.
 2. An assembly according to claim 1, in which the supply lead is insulated, the first portion of the connector element being crimped about a bared portion of an electrically conductive core of the supply lead, and the second portion of the connector element being crimped about the insulation of the supply lead.
 3. An assembly according to claim 1, in which the projection is in the form of a tube having a longitudinally extending open seam, the supply lead being positioned within the projection.
 4. An assembly according to claim 3, in which the wire of the coil passes through the projection.
 5. An assembly according to claim 4, including a channel in the flange of the bobbin in line with the projection and serving to guide the wire of the coil into the projection.
 6. An assembly according to claim 1, in which the first portion of the connector element has a plurality of inwardly extending serrations which serve to break through the enamel coating on the wire of the coil during the crimping operation. 